Refitting the Scuppers for Heavy Weather Confidence

Jun 14, 2025
185
Hunter 1981 30 Chesapeake
Yesterday I refit my deck drains—Hunter’s original sizing was all over the place, so I standardized everything. Now the deck scuppers are a full one-inch ID (about double what they were), with the cockpit scuppers getting bumped to 1.5-inch. Hurricane season’s coming, and if I ever take green water, I want it gone yesterday.

Here’s the weird part: drilling through the hull for the new fittings, I hit a layer of… something. Feathery, dry, foam-like—sandwiched in the laminate, above the waterline. The area had a small leak, but the mystery layer wasn’t soaked.

Is this a normal construction method for above-waterline scuppers? Some kind of core? Or am I looking at evidence of past water ingress? Would you grind it back and glass over, or just dry it out and fill with epoxy?

Photos attached—curious what you all think.
 

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